Poulan 3800 Bar Chain Replacement

I purchased a Oregon brand replacement bar & chain combo which listed the Poulan 3800 as one of the models which it fit. I put the bar and chain on the saw, but I cannot get the chain tensioner adjusting pin into the slot in the bar. It is close, but off by about 1/16". Is it possible I got a defective bar? Or more likely I am not doing something correctly during the install.

I have been screwing around with this for a couple of hours, and I became so focused on the problem that I forgot how the 2 metal plates go back into the saw. I think one goes on either side of the bar, behind the plastic side casing. But I am not sure which one goes on which side, and it seems they can be installed in several different directions (concave or convex) or they can be rotated 180 degrees and still fit over the 2 studs to which the 2 bolts (on outside of the case) hold everything together.

If it helps I can email photos of the 2 metal plates.

Can someone please help me before I lose my mind? I am so ticked off I cannot think straight, so I hope this message is clearly written.

Thanks in advance for any assistance.

TJ

This leads me to believe one of the following is happening: 1. - the little metal piece that holds the adjusting screw is loose which allows the adjusting screw to cock sideways instead of drawing up the chain, or 2. - possibly the adjusting pin is worn out (it looks slightly rounded on one side, or 3. - it may not be the correct adjusting pin (maybe it got switched when the saw was in the shop for a blade sharpening).

On the next business day I am going to try to contact Poulan to see if I can get a repair manual\parts manual to determine the price and availability of a new adjusting screw assembly. I am hoping I can replace the metal piece holding the adjusting screw instead of having to buy a complete new side case.

It seems the price of new saws has decreased to the point where it might be more cost effective to replace the saw instead of buying new parts and fixing the old saw.

For the time being what I am doing is hanging the saw using a small hole in near the tip of the bar and letting the weight of the saw draw the chain tight, and then I lock down the 2 nuts holding the bar to the saw.

This was a bit of a pain initially but after a bit of cutting with the new chain, it seems the chain has stopped stretching so I can cut for a good while before the chain needs to be tightened again. At least this work-around allowed me to clear a couple of oaks which dropped in my rear yard during a recent storm.

I now have more time to focus on making a proper repair to the Timbermaster 3800. Then I have 2 more saws waiting for my attention - another Poulan and a McCullough. These other 2 saws are not as powerful as the 3800 but I am hoping out of the 3 saws I can get at least one good cutting saw ready before the next storm hits. More on those saws later.

Thanks again for everyone's help.

~TJ

The bar plates go on either side of the bar, large end towards the from, with the bent "wings" pointing away from the bar. Make sure you get the plate with the oiler hole on the saw side.